TATA Motors Xenon User manual

TATA
TATA
TATT
TT
TAA
AA
A XENONXENON
XENONXENON
XENON
Owner's Manual & Service Book
 Mumbai  Pune 
Thisowner’smanualshouldbeconsideredasapermanentpartofthevehicleandmustremainwiththevehicle.
Edition :
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This Owner’s Manual should be kept in the vehicle at all times.
This book will help you to understand the vehicle better, maximise uptime of the vehicle & obtain
better performance at optimum cost.
The recommended routine maintenance servicing along with any running repairs that may be required,
should be entrusted to a TATA MOTORS Authorised Workshop to ensure that only latest methods and
genuine TATA MOTORS replacement parts are used for the continued reliability, safety and performance of
thevehicle.
Some of the items / accessories / features shown / given in this book may not be fitted on your vehicle, but
they are applicable for other versions of XENON.
(C) Copyright 2004 TATA MOTORS
All rights reserved. The material in this manual may not be reproduced or copied, in whole or in part, in any
form without written permission from TATAMOTORS.
The information and specifications given in this book are valid as on the date of printing. TATA MOTORS
Limited reserves the right to make changes in design and specifications and/or to make additions to or
improvementsin this product without obligation toinstall them on products previously sold.
Inthe event of the Vehicle being sold, please ensure thatthismanual is leftin the vehicle for the referenceof
thenewowner.
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DEAR CUSTOMER,
We are pleased to hand over to you a TATA XENON vehicle manufactured by TATA MOTORS
where quality is the watchword and major attention is paid even to minor details at all stages
of manufacture.
Please carefully read this book, it helps you to know your vehicle better, to ensure your vehicle
is ready for operation at all times and to obtain better performance at optimum operating costs.
All service and maintenance tasks should be carried out at the specified service intervals.
Some of the items / accessories / features shown / given in this book may not be applicable
for your vehicle, but may apply to other versions of this model.
For any further assistance, kindly contact the nearest TATA MOTORS authorised workshop
dealership or our offices.
We wish you good luck and prosperity.
Foreword
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Contents
Getting Started
Key & Door Lock 50
Child Lock 51
Seats, Seat Adjustments & Seat Belts 52
Steering Wheel Adjustment 56
Driving
Checks Before Driving 57
Safety Checks 58
Fuel Saving Tips 59
Starting & Stopping The Engine 61
Gear Shifting 62
Braking 66
Driving In Adverse Conditions 67
Incase Of Emergency
Jack Location / Warning Triangle 69
Flat Tyres Replacement 69
Spare Wheel 71
Limp Home Mode 72
Starting The Engine With Jump Leads 73
Know your Xenon 6
Warranty - Terms & Condition 8
Environmental Care 10
Xenon At A Glance
Driving Controls 12
Instrument Cluster 13
Steering Lock and Ignition Switch 20
Combi Switch 21
Head Lamp Levelling 24
Transfer Case Switch 25
Music System, Analog Clock & Antenna 26
Heating, Ventilation & Air Conditioning 27
Grab Handle & Cigarette Lighter 32
Lamps 33
Sun Visor & Mirrors 36
Rear View Mirror 37
Glove Box, Cup Holder & Utility Pockets 38
Window Glass Operations 39
Fuel Flap Opening 40
Gear Shift Lever & Parking Brake 41
Anti Theft / Immobiliser System 42
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Contents
Windshield Washer & Tyre 98
Repair of Tyre / Tube 99
Tyre Rotation 100
Wheel Alignment, Balancing & Catalytic
Converter Maintenance 101
Battery 102
Important Technical Information
Fuel, Lubricants & Coolants 103
Oil Filling & Drain Points 106
Technical Specification 107
Information At a Glance (Dimensions) 110
Vehicle Identification
Location of Aggregate Number 111
PDI Service 113
Service Schedule 117
Service Maintenance Schedule 119
Record of Services Performed 124
Record of Repairs Carried Out 126
Towing The Vehicle 72
Routine Service 73
Preliminary Trouble Shooting 74
Electrical Maintenance
Fuses & Relays 82
Bulb Specification 84
Bulb Replacement 85
Vehicle Care
Washing & Cleaning 87
General Precautions 89
Maintenance
Opening & Closing The Bonnet 90
Engine Compartment 91
Air Filter, Engine, & Engine Oil Level 92
Engine Coolant & Brake Fluid Level 93
Power Steering Fluid Level 94
Load Conscious Pressure Reducing Valve 95
Clutch Fluid & Sedimenter 96
Fuel Filter & Priming Pump 97
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TATA XENON is a versatile vehicle. It incorporates
wellknownandprovenfeaturesofTataMotorsprecision
and advanced technology. Easy maneuverability and
economic life cycle cost make this vehicle ideal for
urban and rural areas for operation as pick-up truck,
delivery van, service van, etc.
TATA XENON comes equipped with a TATA DICOR
engine with BS-III compliant norms and having a 5
speedfullsynchromeshgearboxwithoverdrive5thfor
excellent fuel efficiency and tough road gripping tyres
for added traction.
Know Your Xenon
The DICOR Engine has a sophisticated common rail
fuelsystem.It consists ofECU,sensorsandactuators.
The electronic control unit (ECU) is a 32 bit
microprocessor which controls engine fuel injection
parametersandothervehiclerelated parameters. The
ECU receives input from various sensors fitted to the
engine and on the vehicle to decide fuel injection
quantity, fuel timing and number of injections best
suited for the engine to work with maximum fuel
efficiency and safety.
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Know Your Xenon
Other features like vacuum assisted independent
hydraulic brakes on front and rear wheels through
tandem master cylinder and tandem booster. Also
ventilated front brake discs with twin port calipers
provides better braking efficiency and greater safety.
Telescopic shock absorbers and an antiroll bar make
upthefrontindependent suspension set-up. Parabolic
springs coupled at the rear ensure good road holding
and stability. Anergonomicallydesigned cabin with added features
such as adjustable steering column, central locking,
headlamp leveling, power windows, rotary HVAC
controls, electronic cluster, internally adjusted ORVM
for good all-round visibility. Easy access to areas of
dailymaintenance are some of the otheruser-friendly
features.
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Know Your Xenon
WARRANTY - TERMS & CONDITIONS
WE WARRANT each TATA XENON
vehicles& partsthereofmanufactured
byus tobefree fromdefect inmaterial
and workmanship, subject to the
followingterms &conditions :
1. This warranty shall be for 24
monthsOR 75000 kms,whichever
is earlier from the date of sale of
the vehicle, However, for the
vehicles used for commercial
applications(including those used
forhireorrewardvizthoseoperating
with a yellow number plate), the
warranty shall be limited to 24
months or 50,000 kms, whichever
occursearlier.
2. Our obligation under this warranty
shall be limited to repairing or
replacing,freeofcharge,suchparts
ofthevehicle which,inouropinion,
aredefective, onthe vehiclebeing
broughttousortoourdealerswithin
the warranty period. The parts so
repaired or replaced shall also be
warranted for quality and
workmanship but such warranty
shall be co-terminus with this
originalwarranty.
3. Any part which is found to be
defective and is replaced by us
under the warranty shall be our
property.
4. As for such parts as tyres,
batteries, transfer case, rubber
parts,electricalequipmentand fuel
injectionequipment,powersteering
equipment, A.C. equipment not
manufacturedbyusbutsuppliedby
otherparties,thiswarrantyshallnot
apply,butbuyersofthevehicleshall
beentitled to, sofar as permissible
by law, all such rights as we may
have against such parties under
theirwarranties inrespect of such
parts. Our Dealers/TASC’s will
assist the purchaser in taking up
the complaint with the respective
manufacturersandtheirdecisionon
thewarranty willbefinal.
5. This warranty shall not apply if the
vehicle or any part thereof is
repaired or altered otherwise than
in accordance with our standard
repairprocedure, orby anyperson
other than our sales or service
establishments, our authorised
dealers or service centres or
service points in any way so as, in
our judgement which shall be final
and binding, to effect its reliability,
nor shall it apply if, in our opinion
whichshall befinaland bindingthe
vehicle is subjected to misuse,
negligence,improperorinadequate
maintenanceoraccident or loading
inexcess ofsuchcarrying capacity
as certified by us, or such services
as prescribed in our Owner’s
Manual and Service Book are not
carriedoutbythebuyerthroughour
sales or service establishments,
our authorised dealers or service
centres or service points.
6. Thiswarrantyshallnotcovernormal
wearandtearoranyinherentnormal
deteriorationofthevehicleoranyof
itsparts arisingfromthe actualuse
ofthevehicleorany damage dueto
negligent or improper operation or
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Know Your Xenon
WARRANTY - TERMS & CONDITIONS
storageofthevehicle.Thiswarranty
shall not apply to normal
maintenance services viz. oils &
fluid changes, head lamps
focussing, fastener retightening,
wheel balancing, tyre rotation,
adjustmentofvalve clearance,fuel
timing, ignition timing and
consumableslike bulbs,fuel filters
andoilfiltersetc.Thiswarrantyshall
not apply to any damage or
deterioration caused by
environmental pollution or bird
droppings. This warranty shall not
apply to V-belts, hoses and gas
leaks in case of air conditioned
vehicle. Slight irregularities not
recognisedasaffectingthefunction
orqualityofthevehicleorpartssuch
as slight noise or vibration and
defects appearing only under
particularor irregular operationsor
items considered characteristic of
thevehicle.
7. Thiswarrantyshall benullandvoid
if the vehicle is subjected to
abnormal use such as rallying,
racing or participation in any other
competitive sports. This warranty
shall not apply to any repairs or
replacementas aresultof accident
orcollision.
8. Thiswarranty isexpressly inlieuof
all warranties, whether by law or
otherwise, expressed or implied,
andallotherobligations orliabilities
onour partand weneitherassume
norauthoriseanypersontoassume
on our behalf, any other liability
arising from the sale of the vehicle
orany agreementinrelationthereto.
9. Thebuyershallhaveno other rights
except those set out above and
have,particular,norighttorepudiate
the sale, or any agreement or to
claimanyreductionin thepurchase
price of the vehicle, or to demand
any damages or compensation for
losses, incidental or indirect, or
inconvenience or consequential
damages,loss ofvehicle,or lossof
time, otherwise, incurred or
accrued.
10. Anyclaimarisingfromthiswarranty
shall be recognised only if it is
notified in writing to us or to our
concerneddealerwithoutanydelay
soon after such defect as covered
andascertainedunderthiswarranty.
11. Thiswarrantyshallstandterminated
if the vehicle is transferred or
otherwise alienated by the buyer
withoutour priorwritten consent.
12. Wereserveour rightsto makeany
changeor modificationinthedesign
of the vehicle or its parts or to
introduceanyimprovement therein
orto incorporatein thevehicle any
additionalpart oraccessory atany
timewithoutincurring anyobligation
to incorporate the same in the
vehiclespreviously sold.
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Know Your Xenon
ENVIRONMENTALCARE
TATA MOTORS is committed to
producing vehicles using
environmentally sustainable
technologies. A number of
features have been incorporated
inTATAVehicleswhichhavebeen
designedtoensure environmental
compatibility throughout their life
cycle.Wewouldliketoinformyou
that your vehicle meets
appropriateenvironmental norms
and this is being regularly
validated at all stages of
manufacturing.
As a user, you too can protect the
environment by operating your
vehicle in a proactive manner. A
lot depends on you driving style
and the way you maintain your
vehicle. The following points are
provided for your guidance.
Driving
•Avoid frequent and rapid
acceleration.
•Do not carry any unnecessary
weight on your vehicle as it
overloadstheengine.
•Avoid using devices requiring
highpowerconsumptionduring
slow traffic condition.
•It is not advisable to warm up
the engine during first start of
the day by idling, as cold
temperatures within engine
could cause rise in the
emissions such as CO & HC
particulate.
•Monitor fuel consumption
regularlyandifit shows a rising
trend, get the vehicle
immediately attended by an
authorisedTatadealer.
•Switch off engine during long
stops at traffic jams or signals.
Ifsituationdemandsthatengine
bekeptrunning,avoid frequent
revvingoftheengine.Alsoavoid
frequent stopping and
restarting, if uncalled for.
•It is not necessary to rev the
engine before turning it off.
•Shift to higher gears as soon
aspossible . Use each gear up
to 2/3rd of its maximum engine
speed. Recommended gear
shiftspeedarefurnishedinthis
manual.
Maintenance
•Ensurethatperiodicalservices
are carried out regularly by an
authorisedTatadealer.
•As soon as you see any
leakages of oil, fuel, air or
coolant, get it attended to
immediately.
•Useonlyrecommendedbrands
and grades of lubricants and
clean/uncontaminatedfuels.
•Get your vehicle checked for
emission periodically by an
authorisedTatadealer.
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Know Your Xenon
ENVIRONMENTAL CARE
•Ensure that fuel filters, oil filter
etc. are replaced at
recommendedintervals.
•Do not pour used oils or
coolants into sewage drains,
garden soil or open streams.
Dispose used filters and
batteries in compliance with
locallaws.
•It is not recommended that
unauthorised workshops
tamperwiththeengine settings
ortocarryout modifications on
thevehicle.
•Avoid running the vehicle out
offuel,asit can resultinengine
misfire.
•Please adhere to
recommended fuel
specifications while filling up
top.
While carrying out servicing or
repairs, you should pay keen
attention to components given
below which affect emission.
1. Fuel injection pump,
injectors.
2. Air intake and Exhaust
system.
3. Cylinder head for valve
leakage.
4. All filters such as air, oil and
fuel filters.
5. Turbochargerandintercooler
(if fitted.)
6. EGR system components &
Electrical connections.
7. Glow plug timer.
8. Catalytic convertor.
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Xenon At a Glance
DRIVING CONTROLS
1. Air Vents
2. Instrument Cluster
3. Steering Wheel
4. SideAir Vents
5. Horn Pad
6. Accelerator Pedal
7. Brake Pedal
8. Clutch Pedal
9. Music System
10. Ash Tray
11. Parking Brake
12. PowerWindowSwitches
13. Cup Holder
14. Gear Shift Lever
15. Cigarette Lighter
16. A.C. Controls
17. Analog Clock
18. HazardWarningSwitch
19. Glove Box
DRIVING CONTROLS
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INSTRUMENT CLUSTER
Xenon At a Glance
1
2
3
4
5
6
7
8
10
11
12
11
15 14 13
16
18
17
27 21
9
25
24
INSTRUMENT CLUSTER
20 19 22 26
23
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INSTRUMENT CLUSTER
1. Front Fog Lamp Indicator (Green)
2. ‘Check Engine’ Indicator (Red)
3. Door Open Indicator (Red)
4. High WaterLevelIndicatorinSedimenter(Amber)
5. 4WD Low (For 4x4 Vehicles Only) (Green)
6. 4WD High (For 4x4 Vehicles Only) (Green)
7. Rear Fog Lamp Indicator (Amber)
8. MIL Indicator (Amber) If fitted
9. Anti - Theft Indicator (Red)
10. Glow Plug “ON” Indicator (Amber) - If fitted
11. Direction Indicator (Green)
12. Head Lamp Main Beam Indicator (Blue)
13. Engine Low Oil Pressure Indicator (Red)
14. Battery Charging Indicator (Red)
15. BrakeFluidLevelCheck/ParkingBrakeIndicator
(Red)
16. Seat Belt Indicator (Red)
17. TripOdometer
18. CumulativeOdometer
19. ModeSelectorKnob(Odometer)
20. SetKnob(Odometer)
21. HighTemperature Warning
22. LowFuelwarning
23. Over Speed Indicator
24. Speedo Meter
25. RPMMeter
26. FuelGauge
27. TemperatureGauge
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INSTRUMENT CLUSTER
Front Fog Lamp
Indicator (Provision):
Thissymbol(Greencoloured)lights
up when the front fog lamps are
switched‘ON’
Check Engine
Indicator:
This indicates engine condition,
whenamalfunctioningoccursinthe
Engine or EMS (Engine
ManagementSystem).ItRemains
“OFF” in “IGN” position OR
Remains“ON”inrunningposition.
CAUTIONCAUTION
CAUTIONCAUTION
CAUTION
WhenEngineCheck Indicator
comes ON, get the problem
attended immediately, at the
earliest, at an Authorised
serviceoutlet.
Xenon At a Glance
switchin2Hmodeboth 4H and 4L
indicatorlight on instrument panel
shouldglowfor a fewsecondsonly
and go ‘OFF’. Continuous
illumination indicates an electrical
fault.Do not run the vehicle ifboth
4H and 4L indicator are ON. The
4H or 4L indicator light will glow
only when the transfer case is
either in 4H or 4L mode.
Rear Fog Lamp
Indicator (Provision):
This symbol (Amber coloured)
lights up when the rear fog lamps
areswitched ‘ON’.
Turn Signal:
Turnsignallamps can beoperated
only when the ignition supply is
‘ON’andby usingtheturn indicator
switch on the combi switch. The
direction indicator arrow (LHS)
and (RHS) on the instrument
Door Open Warning:
Prior to driving ensure that all the
doorsareproperlyclosed.Ifanyone
of the doors is partially open, the
door open indicator will come on.
In addition to this, if driver’s side
doorisnotproperlyclosedanaudio
beepwillsoundforafewseconds,
when the key is inserted.
Water in fuel sedimenter
indicator:
This light comes on when there is
excesswaterinthefuelsedimenter.
In this case it is recommended to
take your vehicle to nearest
service outlet or drain the water
from the sedimenter yourself.
Please refer to fuel filter and fuel
system in maintenance section.
4H, 4L Indicator:
(* For 4WD model only)
Withignition ‘ON’andtransfer case
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CAUTIONCAUTION
CAUTIONCAUTION
CAUTION
INSTRUMENT CLUSTER
Xenon At a Glance
clusterflashes along with external
indicator lights as selected.
High Beam Indicator:
Symbol lights up when the
headlamp high beam is ‘ON’.
Low Oil Pressure
Indicator:
When the ignition key is turned to
the‘IGN’position,symbollights up
andgoesoffassoonastherequired
engineoilpressureisreachedafter
startingthe engine.
Ifthelowoilpressureindicatordoes
not glow or remains ‘ON’ with the
‘IGN’ on and engine is running, it
indicates a fault in the electrical
circuit/lubricationsystem.Check&
get the problem attended to at an
AuthorisedServiceoutlet.
Battery Indicator:
Symbollights up when the ‘IGN’is
turned ‘ON’ and should go ‘OFF’
afterthe engine starts.
If it remains ‘ON’ while the
engine is running. It indicates
that the alternator is not
functioning. Switch off all
unnecessary electrical
equipmentandgettheproblem
attended to at an Authorised
Serviceoutlet.
Italsolightsupwhenbrakefluid
levelislow.
When ignition key is turned to
“IGN” position, this indicator
lights up and goes off when
enginestarts.
Seat Belt Indicator:
This indicator comes ON with
ignition and goes OFF whenever
the drivers seat belt is fastened.
Odometer and Trip meter
(on LCD):
The odometer records the total
distance the car has been driven.
The trip meter can be used to
measure the distance traveled on
each trip or between fuel fillings.
Keeptrack oftheodometerreading
&followthemaintenanceschedule
regularly for meeting service
requirements.
Parking Brake Indicator
and Low Brake Fluid
Warning Light:
Thisindicatorhasmultiplefunctions
as follows -
It lights up when the parking
brake is applied and goes off
whenparkingbrakeisreleased.
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INSTRUMENT CLUSTER
Xenon At a Glance
Odometer, Trip meter and
Illuminationintensity control on
instrument panel (LCD):
TheinstrumentpanelhasanLCD
to display the following :
MainOdometer(Non- resettable)
- Counts up to 999999 kms
Trip meter A (Resettable) -
Counts up to 1999.9 kms
Trip meter B (Resettable) -
Counts up to 1999.9 kms
Intensity level of instrument
panel illumination – selection
amongpresetlevels.
LCDhastwolinedisplay.Thefirst
linedisplaystheOdometercount.
Thesecondlinedisplayseither of
Trip meter A, Trip meter B,
Intensitylevelofpanelillumination.
The selection and control of
functionsaredonethrough‘MODE’
and ‘SET’ push buttons (knobs)
providedon eithersideoftheLCD.
The‘MODE’knobis used to select
oneof theTripmeterA,Trip meter
B OR Intensity level of panel
illumination.Switching among the
abovethreefunctions can bedone
by pressing the knob.
The panel illumination intensity
varies among preset levels as
follows:
= Min
= = = = Max
This display returns to Trip meter
A after a few seconds of intensity
level selection, if left in this mode.
The ‘SET’ knob is used to control
the chosen function. Pressing the
knob for a few seconds resets the
chosen trip meter and varies the
intensity level of instrument panel
illumination.
Intensity Level Indicator
NOTICE
Main Odometer and Trip
Meter - Aindication will remain
on display even if the ignition
key is removed.
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INSTRUMENT CLUSTER
Xenon At a Glance
Hazard Warning:
This can be operated without
ignition ‘ON’. Press the hazard
warning switch (red knob) on the
centre of the dash board, all turn
indicator lights will flash
simultaneously to warn the other
road users about any hazardous
conditionofthecar. Press theknob
again to switch ‘OFF’ the hazard
function.
NOTICE
If lights do not blink or blink
rapidly, it is an indication of
problem in the blinker electrical
system or the indicator bulb at
front or rear has fused. Get it
rectified immediately.
Lock Indicator Warning
Light:
If it blinks on the dashboard,
vehicle cannot be driven without
pressing UNLOCK button on the
Userremote.
Over Speed Indicator:
It will Indicates when the vehicle
speed exceeds 120 km/hrs.
Low Fuel Indicator:
(Amber/Orange) :
Itcomesonwhenfuellevelreaches
10 liters (approx) in tank alerting
the user to fill fuel.
Over Speed
Indicator
Low Fuel
Indicator
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INSTRUMENT CLUSTER
RPM Meter:
The meter indicates engine speed in revolutions per
minute(rpm)Change gears at appropriate engine rpm
and vehicle speed to get optimum fuel economy. The
permitted engine rpm upper limit is the start of Red
Zone on the dial.
Fuel Gauge:
The fuel gauge indicates the approximate fuel level in
the tank. Refill the fuel tank at the earliest, before the
needle touches the red band on the gauge. At this
point, approx.10 liters of fuel is remaining in tank and
it is advised to get fuel filled immediately
Temperature Gauge:
The gauge indicates the temperature of the engine
coolant. The red zone at ‘H’ indicates temperature
higherthanthenormal.Avoiddriving,whenthepointer
is in the red zone. It indicates engine overheating,
whichmaybeduetoinsufficientcoolant in the radiator
or due to any other defect. At this stage take the car
to the nearest Tata Authorised Service outlet for
necessaryattention.
Never remove the cap from the coolant reservoir
when the engine is hot. Do not restart the engine
until the problem has been duly attended.
The speedometer: The speedometer indicates the
car speed in km/hr.
Temperature
Gauge High
Temperature
Warning
Speedo Meter
Xenon At a Glance
Fuel Gauge
Low Fuel
Indicator
RPM Meter
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NOTICE
LOCK:
You can insert or remove the key
only in this position. The steering
column is locked when the key is
removed.
WARNING
Do not remove the key while
driving.It will lock the steering
and can cause loss of control.
Removethekey onlywhenthe
vehicle is parked.
ACC:
By turning key to ACC position
power supply to accessories is
switchedON.
START:
Turn the key further clockwise to
theSTARTposition(springloaded)
tostarttheengine.As soon asthe
engine starts release the ignition
key to ON position.
Do not crank the engine more
than 10 secs. continuously.
Iftheengine doesnotstartwait
for 30 secs. before cranking it
again. Release the key
immediately after starting the
engineotherwise startermotor/
flywheel ring may get
damaged.
STOP:
Byturningtheignition key fromON
position toACC or LOCK position,
engine can be stopped.
STEERING LOCKAND IGNITION SWITCH
Xenon At a Glance
Steering Lock and Ignition
Switch:
Key of ignition switch is common
forthedoorlock,steeringlockand
glovebox lock.
The ignition switch is on the right
side of the steering column. It has
four positions. Turn the key
clockwiseforfurther functions.
LOCK - SteeringLocked
ACC - Accessories ‘ON’
ON - Allelectricals ‘ON’
START - Engine crank
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